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The speed of production of care products is jaw-dropping. In just one minute, 3000 pieces of product will be produced from the production line. In order to maximize production capacity, products should be diverted in the packaging process. To this end, the Optima Nonwovens Division offers two systems. They have their own characteristics and are not the same. The relevant solutions are lane separation systems (Splitter) and multi-lane discharge stacking systems (Multiple Discharge Stacker). Both systems receive sanitary napkins or pad products from the production line online.

The reason for this development is the rapid increase in the speed of the production line. Until a few years ago, this growth was also reflected in the packaging system consisting of stackers and bagging machines. But at the same time, the product handling capacity of the packaging machine is approaching the physical limit. This, coupled with the trend towards smaller packaging, reduces the efficiency of the production line. Process stability is always the first priority-a purely theoretical maximum capacity makes no sense.

Therefore, it is time to think about new packaging solutions, in order to continue to fully realize the potential of the production line in the packaging process. In view of this, the Optima Nonwovens Division started to develop two dedicated systems.

different characteristics

The characteristics of the two solutions "lane separation system" and "multi-lane discharge stacking system" are different.

The lane system is mainly used in the first step of the packaging process, and its task is to divert the product in different directions. Paddle ("Flipper") setting mode: The product can be dispensed in different directions in turn. For example, the product can be conveyed in five straight lines, three to the right, and then cyclically. After the separation, there are two complete packaging systems, which are composed of stackers and bagging machines.

Another option is the multi-channel outfeed stacker: the product goes directly into a dedicated stacker. The stacker features two (or three) integrated discharge units. Two separate baggers can be started through these discharge units (the third discharge unit is used for product testing or manual packaging). The program can also customize the number of pieces of each discharge 2.

Thus, the layout of the entire packaging system looks like the letter "h" from above ". The packaging machines are now arranged parallel to each other. This is one of the key elements in comparing the two systems. In addition, there are other systematic differences between the two schemes.

Flexible installation, ergonomic design and reasonable layout: The packaging scheme of configuring the lane separation system has many advantages in these aspects. This allows for a better view of the space situation and the workflow. The layout can be implemented in the form of "T" and "h. This also facilitates access to the equipment area, which is conducive to reasonable layout and more ergonomic. In the case of a conveyor unit that can place bags next to the bagging machine, one employee can operate the entire device.

Land Requirement: The two systems have different land occupation requirements, which ultimately depend on the customer's field conditions.

Operation and Maintenance: Compared with the multi-channel discharge stacking system, the operation and maintenance of the lane separation system is relatively more complicated. The multi-channel discharge stacking system can be comparable to the one-way packaging line in this respect. Therefore, operation and maintenance are extremely simple.

Flexible specifications-simultaneous processing of different pieces: For the solution using the separation system, the quantity can be arranged as flexibly as the independent packaging system, and the smallest and largest number of packages can be produced at the same time. The multi-channel discharge stacking system may have some limitations in this regard, and sometimes it is not possible to produce all the number of pieces at the same time. (In a multi-channel discharge stacker, one discharge unit can be moved sideways: the distance between the discharge units is matched with the number of pieces of each package for combined analysis.

Size Change I-Change the number of packages: When changing the number of packages, the processing of the two systems is different. The same thing is that one packaging machine can be changed in specifications while another packaging machine is in production operation. However, the multi-channel discharge stacking system has to stop production briefly in order to reset the stacker and replace the specifications. The split-lane solution that can replace the number of pieces without stopping production has obvious advantages, which is ultimately reflected in operating costs.

Specification Replacement II-Products of Different Thickness: The lane separation system has a slight advantage in this regard. Compared with the overall longer and single stacker blade chain in the multi-channel discharge stacking scheme, the two stacker blade chains of the lane separation system can be adjusted faster.

Process stability in case of component failure: It depends on the specific situation. Problems with the upstream system always result in downtime of subsequent components. This means that if the multi-channel discharge stacking system fails, both bagging machines will not work. The same applies to the lane separation system. If an error occurs in the lane separation system, the entire system stops operating. However, in the lane system solution, if one stacker or bagging machine fails/needs maintenance, the second processing line can still continue production. In the multi-channel outfeed stacker solution, if one bagging machine fails, the second bagging machine can also be used to continue production.

Maximum capacity: In the scheme using the lane separation system, the packaging speed can be as high as 280 bales/minute (2 x 140 bales/minute). In the multi-channel discharge stacking system, the packaging speed can reach 200 bales/minute (2 x 100 bales/minute). The difference is even more pronounced compared to the rate of product from the receiving processing line. The separation solution can receive 3000 pieces of product per minute, while the multi-channel discharge stacking system can receive up to 1600 pieces, mainly because the chain of blades is heavier. So there is a clear advantage in terms of capacity-but ultimately the capacity of the production line must be synchronized reasonably and efficiently (all performance data depends on the packaging material used, the size of the packaging and the product specifications).

investment cost: In terms of purchase costs, the advantages of multi-channel discharge stacking system are obvious. The reason is that it saves the cost of a lane separation system or a second stacker.

Operating costs: Both systems are modular in design. Thus, the machine configuration can be adapted to individual requirements in practice.

The company will evaluate the technical level, potential and cost performance of each equipment. The deciding factor is that the manufacturer of the hygiene product can choose the best production run. The lane separation system and the multi-lane discharge stacking system provide special gains for this. Optima Nonwovens Division is willing to work with customers to find the best solution.

This article is from Optima Nonwovens